Ceiling fan

ABSTRACT

The invention relates generally to fans, and in particular to ceiling fans. The ceiling fan includes a motor with a shaft that rotates with the rotation of the motor. A fan blade assembly is coaxially coupled to the motor shaft. The motor and fan blade assembly are substantially remote to each other.

PRIOR RELATED APPLICATIONS

Not applicable.

FEDERALLY SPONSORED RESEARCH STATEMENT

Not applicable.

REFERENCE TO MICROFICHE APPENDIX

Not applicable.

FIELD OF THE INVENTION

The invention is directed to a ceiling fan.

BACKGROUND OF THE INVENTION

A typical ceiling fan includes a down rod assembly suspended from the ceiling with a motor shaft connected to a lower portion of the down rod assembly. A motor body rotates about the motor shaft. Blade mounting arms, also referred to as blade irons, are connected to the motor body and extend out of an opening of the motor housing or below the motor housing.

Motors used in the art tend to be proximate to the fan blades. Typically, fan blades are connected to the motor via blade irons. However, motors tend to be cumbersome and unattractive causing manufacturers to encase or mask the motor within a housing. Unfortunately, the bulk of the motor limits the aesthetics of the ceiling fan housing. Furthermore, when the downrod assembly positions the ceiling fan a distance from the ceiling, horizontal movement of the ceiling fan may occur during operation.

SUMMARY OF THE INVENTION

Some embodiments of the invention provide a ceiling fan comprising a motor assembly, a shaft having a first end and a second end, and a hub having a fan blade assembly wherein the first end of the shaft is coaxially coupled to the motor assembly and the second end of the shaft is coaxially coupled to the fan blade assembly, and wherein the motor assembly rotates the shaft and the shaft rotates the fan blade assembly. In such embodiments of the invention, the motor assembly and fan blade assembly may be substantially remote to each other. In some embodiments of the invention, the shaft is coupled to the motor assembly via a first attachment mechanism and the shaft is coupled to the fan blade assembly via a second attachment mechanism. In yet other embodiments of the invention, the first attachment mechanism comprises a coupling interface. In yet other embodiments of the invention, the second attachment mechanism comprises a mechanical fastener.

Some embodiments of the invention provide a system for supporting a ceiling fan assembly having a motor, a motor housing, a fan blade assembly and a downrod, the system comprising coupling means for coupling the ceiling fan assembly to a support surface and supporting at least some of the weight of the ceiling fan assembly, and stability means for reducing the amount of horizontal movement of the ceiling fan assembly. In some of such embodiments, the stability means comprise a plurality of cables. In some embodiments of the invention, the cables extend from the coupling means to an upper portion of a hub which is coupled to the fan blade assembly. In yet other embodiments of the invention, the upper portion of the hub is static during the operation of the ceiling fan. In yet other embodiments of the invention, the cables comprise a tensioning mechanism which adjusts to secure the ceiling fan assembly to the coupling means and the upper portion of the hub.

Some embodiments of the invention provide a system for attaching a light kit to a ceiling fan assembly having a motor, a motor housing, a fan blade assembly and a downrod, and comprising an inner downrod, an outer downrod, and a sleeve wherein the sleeve and the inner downrod are stationary during operation, and wherein the outer downrod is coupled to the fan blade assembly and rotates with the motor, and the light kit is coupled to the inner downrod.

In yet other embodiments of the invention a system for minimizing horizontal movement of a ceiling fan assembly having a motor and a fan blade assembly, the system comprising a support ring, one or more cables, and a hub wherein the support ring couples the ceiling fan assembly to the ceiling, and wherein the cables couple the support ring to the hub is provided. In some such embodiments the cable further comprises a tensioning mechanism for tightening or lessening the tension in the cables. In some embodiments of the invention, the hub is further coupled to the fan blade assembly and the hub is stationary during operation and the fan blade assembly rotates with the motor during operation.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, exemplify the invention and together with the description, serve to explain the principles of the invention.

FIG. 1 shows a side elevation view of an embodiment of the invention.

FIG. 2 shows an enlarged cut-away view of the embodiment in FIG. 1.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Reference will now be made in detail to embodiments of the invention, an example of which is illustrated in the accompanying drawings.

Referring to FIGS. 1 and 2 showing an embodiment of the invention, a ceiling fan 10 generally includes a mounting assembly 12, a motor assembly 14, a downrod assembly 16, a hub assembly 18, and a light kit 20. In a preferred embodiment, the motor assembly 14 and the hub assembly 18 are coaxially coupled via the downrod assembly 16.

The ceiling fan 10 is connected to the ceiling via the mounting assembly 12. The mounting assembly 12 connects to the ceiling, or other support surface, on one side and couples to the motor assembly 14 on the other side. Electrical wires for powering and controlling the ceiling fan 10 pass through the mounting assembly 12 to the motor assembly 14. The mounting assembly 12 may be an interface plate that connects to a junction box in the ceiling. The interface plate also supports some of the weight of the ceiling fan 10. Although an interface plate is illustrated as connecting the ceiling fan 10 to the ceiling, other commonly known mechanical methods of coupling the ceiling fan 10 to the ceiling or other support surface are contemplated as being included in the present invention, and include, without limitation, mechanical fasteners, and the like.

Referring to FIG. 2, the motor assembly 14 includes a housing 100 and a rotor 102. The rotor 102 may be situated within the housing 100. During operation, the housing 100 remains stationary while the rotor 102 rotates. The housing 100 also supports some of the weight of the ceiling fan 10. The rotor 102 further includes a shaft (not shown) that passes through the rotor 102 and does not rotate during operation. The shaft is a passageway for allowing a plurality of electric wires 106 to pass therethrough.

The motor assembly 14 is coupled to the downrod assembly 16. In some embodiments, the rotor 102 is coupled to the downrod assembly 16. The downrod assembly 16 consists of an inner downrod 28, an outer downrod 30 and a sleeve 32. The downrod assembly 16 may be any suitable length for operation of the ceiling fan 10. In alternate embodiments, the downrod assembly 16 is any length that one skilled in the art is able to design and engineer having structural support and aesthetic appeal.

The inner downrod 28 has a first end 34 coupled to the shaft which passes through the rotor 102. The inner downrod 28 remains stationary during operation and has a passageway therethrough for passing the plurality of electrical wires 106 through to the light kit 20. The electrical wires 106 may be used for powering and controlling the light kit 20. The inner downrod 28 is coupled at the first end 34 to the shaft by any commonly known mechanical attachment methods, such as, but not limited to couplings, pins, screws, snap fits, spring loaded connectors and the like, including a plurality of mechanical fasteners. Opposite the first end 34 is a second end 36 of the inner downrod 28 that is coupled to the light kit 20. Although a mechanical fastener is illustrated as coupling the inner downrod 28 to the light kit 20, other commonly known mechanical methods of coupling the inner downrod 28 to the light kit 20 are contemplated as being included in the present invention, and include, without limitation, couplings, pins, screws, snap fits, spring loaded connectors and the like including a plurality of mechanical fasteners. The light kit 20 does not rotate about an axis defined by the downrod assembly 16 during operation.

The outer downrod 30 rotates with the rotor 102 during operation via the coupling assembly 22. The coupling assembly 22 may be a mating interface. In a preferred embodiment, the coupling assembly 22 also includes one or more couplings. The mating interface includes a first interface 24 on the rotor 102 and a second interface 26 on the outer downrod 30 of the downrod assembly 16. The first interface 24 and the second interface 26 interconnect with each other. Although a mating interface which includes a plurality of couplings is illustrated as coupling the rotor 102 to the outer downrod 30, other commonly known mechanical methods of coupling the rotor 102 to the outer downrod 30 are contemplated as being included in the present invention, and include, without limitation, mechanical fasteners, pins, screws, spring loaded connectors and the like. The first interface 24 may be an attachment to the rotor 102. In a preferred embodiment, the first interface 24 is coupled to the rotor 102 by a plurality of fasteners. In alternate embodiments, any commonly known mechanical fastener may be used to couple the first interface to the rotor 102, such as, but not limited to mechanical fasteners, pins, screws, spring loaded connectors and the like. The second interface 26 may be molded as part of the outer downrod 30 or may be coupled to the outer downrod 30. The second interface 26 may also include one or more bearing assemblies 108.

The second interface 26 of the coupling assembly 22 is typically on a first end 38 of the outer downrod 30. In a preferred embodiment, the second interface 26 is coupled to the outer downrod 30 by a plurality of fasteners. In alternate embodiments, any commonly known mechanical fastener may be used to couple the second interface 26 is coupled to the outer downrod 30, such as, but not limited to mechanical fasteners, pins, screws, spring loaded connectors and the like.

The hub 18 includes an upper portion 46 which remains stationary during operation of the ceiling fan and a fan blade assembly 120 which rotates during operation of the ceiling fan. Opposite the first end 38 of the outer downrod 30 is a second end 40 which is coupled to the fan blade assembly 120. Although a mechanical fastener 200, such as a set screw, is illustrated as coupling the second end 40 of the outer downrod 30 to the fan blade assembly 120, other commonly known mechanical methods of coupling the outer downrod 30 to the fan blade assembly 120 are contemplated as being included in the present invention, and include, without limitation, pins, screws, threaded connectors, spring loaded connectors and the like, including a plurality of fasteners 200. The outer downrod 30 encircles the inner downrod 28. The outer downrod 30 and the inner downrod 28 are not fixedly coupled, allowing them to operate independently. In some embodiments, there may be one or more bearing assemblies between the outer downrod 30 and the inner downrod 28.

Both the outer downrod 30 and the inner downrod 28 are encased by the sleeve 32. The sleeve 32 has a first end 42 and a second end 44. The first end 42 of the sleeve 32 is coupled to the motor housing 100. The sleeve 32 remains stationary during operation. Although a mechanical fastener 202, such as a screw, is illustrated as coupling the first end 42 of the sleeve 32 to the motor housing 100, other commonly known mechanical methods of coupling the first end 42 of the sleeve 32 to the motor housing 100 are contemplated as being included in the present invention, and include, without limitation, pins, screws, spring loaded connectors and the like, including a plurality of mechanical fasteners. The second end 44 of the sleeve 32 is coupled to the upper portion 46 of the hub 18. The upper portion 46 of the hub 18 remains stationary during operation. Although a mechanical fastener 58 is illustrated as coupling the upper portion 46 of the hub 18 to the sleeve 32, other methods of coupling the upper portion 46 of the hub 18 to the sleeve 32 are contemplated as being included in the present invention, and include, without limitation, pins, screws, spring loaded connectors and the like, including a plurality of mechanical fasteners 58. To reduce the friction between the upper portion 46 of the hub 18 and the outer downrod 30, one or more bearing assemblies 60 may be placed between the second end 44 of the sleeve 32 adjacent to the fan blade assembly 18. To reduce the friction between the fan blade assembly 120 and the inner downrod 28, a bearing assembly 62 may be placed adjacent to the second end 40 of the inner downrod 28.

In some embodiments, a plurality of cables 48 couple the upper portion 46 of the hub 18 to a support ring 50. The support ring 50 is coupled to the mounting assembly 12. Although a nut and bolt assembly is illustrated as coupling the support ring 50 to the mounting assembly 12, other commonly known mechanical methods of attaching the support ring 50 to the mounting assembly 12 may be used and include without limitations, mechanical fasteners, screws, bolts, studs and the like. The number of cables 48 may be determined by one skilled in the art based on mechanical and decorative considerations. Mechanical considerations include removing all degrees of freedom in the horizontal plane for the hub 18. Decorative considerations are based upon aesthetic appeal. In a preferred embodiment, there are three (3) cables 48. In other embodiments, there are one, two or more cables 48. The cables 48 may be used to minimize the amount of horizontal movement of the ceiling fan 10 during operation. In a preferred embodiment, the cables 48 have a first section 52 and a second section 54. The second section 54 includes a tensioning mechanism 56 for tightening or lessening the tension in the cables 48. Although a tensioning mechanism 56 is illustrated in the Figures, other methods of lessening or minimizing the horizontal movement are contemplated as being included in the present invention, and include, without limitation, spring loaded connectors, turnbuckles and the like. Although a plurality of cables 48 are illustrated in the Figures, other methods of lessening or minimizing the horizontal movement are contemplated as being included in the present invention, and include, without limitation, guidewires, chains, and the like.

In some embodiments, the ceiling fan 10 is further coupled to a light source 20. Typically the light source 20 is electrically powered. Such a device may be generally referred to as an electrical device. An electrical device is defined herein as a device powered by alternating current or direct current, for example, or any other conventional electrical power source. The light source 20 is connected in a fixed manner to the second end 36 of the inner downrod 28, i.e., not rotating relative to the motor.

While the invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many modifications may be made thereto without departing from the spirit and scope of the invention. Each of these embodiments, and obvious variations thereof, is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. 

1. A ceiling fan comprising: a motor assembly; a shaft having a first end and a second end; and a hub comprising a fan blade assembly; wherein the first end of the shaft is coaxially coupled to the motor assembly and the second end of the shaft is coaxially coupled to the fan blade assembly, wherein the motor assembly rotates the shaft and the shaft rotates the fan blade assembly.
 2. The ceiling fan of claim 1, wherein the motor assembly and fan blade assembly are substantially remote to each other.
 3. The ceiling fan of claim 1, wherein the shaft is coupled to the motor assembly via a first attachment mechanism and the shaft is coupled to the fan blade assembly via a second attachment mechanism.
 4. The ceiling fan of claim 3, wherein the first attachment mechanism comprises a coupling interface.
 5. The ceiling fan of claim 3, wherein the second attachment mechanism comprises a mechanical fastener.
 6. A system for supporting a ceiling fan assembly having a motor, a motor housing, a fan blade assembly and a downrod, the system comprising: a. coupling means for coupling the ceiling fan assembly to a support surface and supporting at least some of the weight of the ceiling fan assembly; and b. stability means for reducing the amount of horizontal movement of the ceiling fan assembly.
 7. The system of claim 6, wherein the stability means comprises a plurality of cables.
 8. The system of claim 7 further comprising a support ring and wherein the cables extend from the support ring to an upper portion of a hub which is coupled to the fan blade assembly.
 9. The system of claim 8, wherein the upper portion of the hub is static during the operation of the ceiling fan.
 10. The system of claim 7, wherein the cables comprise a tensioning mechanism which adjusts to secure the ceiling fan assembly to the coupling means and the upper portion of the hub.
 11. A system for attaching a light kit to a ceiling fan assembly having a motor, a motor housing, a fan blade assembly and a downrod, the system comprising: a. an inner downrod; b. an outer downrod; and c. a sleeve wherein the sleeve and the inner downrod are stationary during operation, wherein the outer downrod is coupled to the fan blade assembly and rotates with the motor, and the light kit is coupled to the inner downrod.
 12. A system for minimizing horizontal movement of a ceiling fan assembly having a motor and a fan blade assembly, the system comprising: a. a support ring; b. one or more cables; and c. a hub wherein the support ring couples the ceiling fan assembly to the ceiling, wherein the cables couple the support ring to the hub.
 13. The system of claim 12 wherein the cable further comprises a tensioning mechanism for tightening or lessening the tension in the cables.
 14. The system of claim 12 wherein the hub is further coupled to the fan blade assembly and the hub is stationary during operation and the fan blade assembly rotates with the motor during operation. 